Bradford White PDX1-40S6FBN User manual

Brand: Bradford White

Model: PDX1-40S6FBN

Category: Water heaters & boilers

Type: User manual

Save this manual for future reference

Manual 238-49770-00B

SERVICE

MANUAL

Troubleshooting Guide

and Instructions for Service

(To be performed ONLY by

qualified service providers)

Models Covered

by This Manual:

PDX140S*F(BN,SX,CX)

PDX150S*F(BN,SX,CX)

PDX440S*F(BN,SX)

PDX450S*F(BN,SX)

PDX250T*F(BN,SX,CX)

PDX265T*F(BN,SX,CX)

PDX275T*F(BN,SX,CX)

PDX50S60F(B,S,C)*(N,X)

PDX65S65F(B,S,C)*(N,X)

PDX75S70F(B,S,C)*(N,X)

(*) Denotes Warranty Years

Powered Direct Vent Gas Water Heaters

PDX Series

Table of Contents

Page PDX Service Procedure

Introduction 4 - - -

How to use this manual 5 - - -

Tool required for service 5 - - -

Specifications 6 - - -

Control Timings 9 - - -

Sequence of Operation 10 - - -

Troubleshooting 13 - - -

Burner Inspection, Cleaning and Replacement 17 I

Pilot Testing, Cleaning and Replacement 19 II

Pressure Switch Testing and Replacement 20 III

Blower Testing and Replacement 22 IV

Blower Temperature Switch Testing and Replacement 24 V

Gas Control & Thermal well Testing & Replacement 26 VI

Flammable Vapor Sensor Testing & Replacement 30 VII

Safety Circuit Voltage Trace 31 VIII

115VAC Circuit Trace 32 IX

Dip Tube inspection and Replacement 33 X

Anode Inspection and Replacement 34 XI

Flue Baffle Inspection and Replacement 35 XII

Inner Door Removal, Inspection & Replacement 36 XIII

Glossary of Terms 40 - - -

Parts List 41 - - -

Page 2

WARNING: If the information in these instructions is

not followed exactly, a fire or explosion may result

causing property damage, personal injury, or death.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electrical switch; do not use any

phone in your building.

Immediately call your gas supplier from a neighbor's phone.

Follow the gas supplier's instructions.

If you cannot reach your gas supplier, call the fire

department.

Installation and service must be performed by a qualified

installer, service agency or the gas supplier.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable,

combustible, or corrosive vapors and liquids in the

vicinity of this or any other appliance.

CAUTION

Incorrect operation of this appliance may

create a hazard to life and property and

will nullify the warranty.

DANGER

Do not store or use gasoline or other

flammable, combustible, or corrosive

vapors and liquids in the vicinity of this

or any other appliance.

IMPORTANT

Before proceeding, please inspect the

water heater and its components for

possible damage. DO NOT install any

water heater with damaged components.

If damage is evident then please contact

the supplie

r where the water heater was

purchased or the manufacturer listed on

the rating plate for replacement parts.

WARNING

Water heaters are heat producing appliances. To avoid

damage or injury, do not store materials against the

water heater or vent-air intake system. Use proper care

to avoid unnecessary contac

t (especially by children) with

the water heater and vent-air intake components.

UNDER NO CIRCUMSTANCES MUST FLAMMABLE

MATERIALS, SUCH AS GASOLINE OR PAINT THINNER BE

USED OR STORED IN THE VICINITY OF THIS WATER

HEATER, VENT-AIR INTAKE SYSTEM OR IN ANY

LOCATION FROM WHICH FUMES COULD REACH THE

WATER HEATER OR VENT-AIR INTAKE SYSTEM.

WARNING

DO NOT ATTEMPT TO LIGHT ANY GAS APPLIANCE IF YOU

ARE NOT CERTAIN OF THE FOLLOWING:

Liquefied petroleum gases/propane gas and natural gas

have an odorant added by the gas supplier that aids in

the detection of the gas.

Most people recognize this odor as a “sulfur” or “rotten

egg” smell.

Other conditions, such as “odorant fade” can cause the

odorant to diminish in intensity, or ”fade”, and not be

as readily detectable.

If you have a diminished sense of smell, or are in any

way unsure of the presence of gas, immediately contact

your gas supplier from a neighbor's telephone.

Gas detectors are available. Contact your gas supplier, or

plumbing professional, for more information.

CAUTION

If sweat fittings are to be used DO NOT apply heat to the

nipples on top of the water heater. Sweat the tubing to

the adapter before fitting the adapter to the water

connections. It is imperative that heat is not appli

ed to

the nipples containing a plastic liner.

WARNING

FAILURE TO INSTALL AND MAINTAIN A NEW, LISTED 3/4” X

3/4” TEMPERATURE AND PRESSURE RELIEF VALVE WILL

RELEASE THE MANUFACTURER FROM ANY CLAIM THAT

MIGHT RESULT FROM EXCESSIVE TEMPERATURE AND

PRESSURES.

WARNING

Hydrogen gas can be produced in an operating water

heater that has not had water drawn from the tank for a

long period of time (generally two weeks or more).

Hydrogen gas is extr

emely flammable. To prevent the

possibility of injury under these conditions, we

recommend the hot water faucet to be open for several

minutes at the kitchen sink before you use any electrical

app

liance which is connected to the hot water system. If

hydrogen is present, there will be an unusual sound such

as air escaping through the pipes as hot water begins to

flow. Do not sm

oke or have open flame near the faucet

at the time it is open.

CAUTION

Turn off or disconnect the electrical power supply to the

water heater before servicing. Label all wires prior to

disconnection when servicing controls. Wiring errors can

cause improper and d

angerous operation. Verify proper

operation after servicing.

Page 3

PDX Series

Page 4

Introduction

The new Bradford White PDX1, PDX2 and PDX4 water heaters are designed to provide

reliable performance with enhanced standard features. New design features include reliable

spark to pilot ignition system, enhanced diagnostics, simplified servicing, significantly quieter

operation, additional vent lengths and certified FVIR technology.

Spark to Pilot Ignition System - employing the spark to pilot ignition system promotes

reliable and consistent pilot and main burner ignitions to provide hot water on demand.

Integrated Immersion Thermostat/Gas Control Valve with LED - was developed for ease

of troubleshooting by providing simple diagnostic codes to pinpoint an installation or

component performance issue.

New Powerful Blower - will eliminate problems with difficult venting situations.

Quieter and Cooler Blower Operation - blower noise is significantly reduced for both

interior and exterior environments. Cooler operation increases blower life by reducing bearing

wear and noise.

Rugged Wiring Connections - receptacle type connections promote error free wiring.

Increased Vent Lengths - increased venting performance is achieved while maintaining

Energy Factor & FHSR performance.

The PDX1, PDX2, and PDX4 water heaters use a combustion system were flue gases are

combined with dilution air to reduce the flue gas temperature in the blower, combustion air and

dilution air are drawn from outside the building. The diluted flue gases are evacuated to the

exterior through non metallic vent materials. The gas control maintains water temperature,

ignition sequence and regulates gas flow. A safety circuit consisting of a pressure switch and

blower temperature switch verifies proper conditions exist for safe and reliable operation. If a

situation outside of normal operating parameters exists, the gas control diagnostic LED will

flash a code to positively identify an operational issue.

This service manual is designed to facilitate problem diagnosis and enhance service efficiency.

To further promote quicker service times the new gas valve can be removed and replaced

without draining the water heater. A special tool is required and will be provided with each gas

valve kit shipped from our Service Parts department.

Please read the service manual completely before attempting service on this new series of

power vent models.

How the Safety System Works

During normal operation, air for combustion is drawn into the water heater though the vent pipe from outside your

building. The air travels into the closed combustion chamber. The air then mixes with in a normal manner with

supplied gas and its efficiently combusted, producing very low NOx emissions.

In the unlikely event trace amounts of flammable vapors are present in the area surrounding the water heater, the

sealed combustion system prevents the flammable vapors from reaching the ignition source. In addition the

flammable vapors sensor will stop the water heater from operating if a significant amount of flammable vapors are

present.

PDX Series

Tools Required for Service

It is intended for this manual to be used by qualified service personal for the primary purpose of

troubleshooting and repair of the Bradford White PDX Series water heaters. Understanding the

sequence of operation section of this manual will contribute greatly to troubleshooting the water

heater.

The Honeywell WV4460E Electronic Gas Control will display error codes in the event of abnormal

operation. Error codes are listed in the troubleshooting chart beginning on page 12 of this service

manual. The troubleshooting chart will also indicate the probable cause for the error code and

direct the service professional to a service procedure to properly diagnose the abnormal operation.

In some difficult to diagnose conditions, it may be necessary to isolate the heater from the vent

system to determine the problem.

Contact the Bradford White technical support group immediately if diagnosis can not be made

using the methods described in this service manual.

Page 5

Manometer:A liquid “U” tube type or a digital (magna-helic) type can be used. This

device is used to measure gas and/or air pressure and vacuum.

Multi-Meter:A digital type is strongly recommended. This device is used to measure

electrical values. The meter you select must have the capability to

measure volts AC, volts DC, Amps, micro-amps and ohms.

Electronic Probes: In some cases, standard multi-meter probes will damage or simply

not be effective to obtain certain voltage and ohm reading. It will be

necessary to have special electronic “pin” type multi-meter probes.

These probes are available at most electronic wholesale outlets.

Thermometer: Used to measure water temperature. An accurate thermometer is

recommended.

Water Pressure Gage: Used to measure water supply pressure. Also used to determine tank

pressure by adapting to the drain valve of the heater.

Gas Control Service Tool: BWC part number 239-45991-00. A specialized tool designed to remove

the gas control from gas control thermal well. Available from

your Bradford White parts supplier.

Various Hand Tools:Pipe wrench, channel locks, open end wrenchs (3/8",7/16",½"),

12" crescent wrench, Allen wrench set, screw drivers (common &

Phillips), ¼" nut driver, pliers (common & needle nose), socket set, side

cutters wire cutters, wire strippers, wire crimpers, torpedo level, small

shop vac, step ladder, and flashlight, 5 gallon pail.

How to Use This Manual

PDX Series

Specifications

Thermal well TCO Limit Residential 188°F (87°C), Commercial 199°F (93°C)

Residential Temperature

Set Point Range

60°F (16°C) to 160°F (71°C) (Approximate temperatures)

Blower Temperature Switch Normally closed, opens @ 155°F (68°C), auto reset @ 128°F (54°C).

Blower 115VAC, 60Hz, 3.1 amps.

Pressure switch

Standard Altitude-Normally open, closes at differential pressure of -.80.

High Altitude-Normally open, closes at differential pressure of -.73.

Power supply Dedicated 115VAC, 60 Hz, 15A

Approved Gas Type Natural or Propane. Unit must match gas type supplied.

Venting System Power direct vent through the wall or vertical through the roof

Approved Vent Materials PVC, CPVC or ABS

Gas Supply Pipe Minimum 1/2" NPT (schedule 40 black iron pipe recommended)

Minimum Clearance

for Servicing

18" from top, 24" from front, 4" sides and rear.

Water Supply Pressure 150 PSI maximum allowable working pressure. Check local codes for supply pressure

Gas Pressure 5.0" W.C. min. for Nat gas, 11.0" W.C. min. for L.P. gas, 14.0" W.C. maximum (Nat. & L.P.)

Commercial Temperature

Set Point Range

80°F (27°C) to 180°F (82°C) (Approximate temperatures)

Page 6

PDX Series

Specifications

Venting Specifications for:

48 Gallon

65 Gallon

75 Gallon

This water heater is approved for installation with the following PVC, CPVC or ABS

Schedule 40 venting material.

The maximum and minimum vent lengths listed on this label are for the exhaust portion of

the vent. The intake portion of the vent must be equal to or less than the length of the

exhaust.

Through the Wall

Terminating

# of

Elbows

Maximum

Length ft (m)

Minimum

Length ft (m)

3" Diameter (7.6 cm) PVC Vent Connector Lengths

1 55 (16.8) 2 (.6)

Through the Wall 2 50 (15.2) 2 (.6)

Through the Wall 3 45 (13.7) 2 (.6)

Through the Wall 4 40 (12.2) 2 (.6)

Through the Wall

Terminating

# of

Elbows

Maximum

Length ft (m)

Minimum

Length ft (m)

4" Diameter (10.2 cm) PVC Vent Connector Lengths

1 95 (29.0) 10 (3.1)

Through the Wall 2 90 (27.4) 10 (3.1)

Through the Wall 3 85 (25.9) 10 (3.1)

Through the Wall 4 80 (24.4) 10 (3.1)

Through the Roof 0 60 (18.3) 7 (2.1)

Through the Roof 1 55 (16.8) 7 (2.1)

Through the Roof 2 50 (15.2) 7 (2.1)

Through the Roof 3 45 (13.7) 7 (2.1)

Through the Roof 0 100 (30.5) 15 (4.6)

Through the Roof 1 95 (29.0) 15 (4.6)

Through the Roof 2 90 (27.4) 15 (4.6)

Through the Roof 3 85 (25.9) 15 (4.6)

Through the Wall 5 75 (22.9) 12 (3.6)

Through the Roof 4 80 (24.4) 15 (4.6)

Vent Tables

Page 7

PDX Series

Maximum

Length ft (m)

Minimum

Length ft (m)

45 (13.7) 2 (.6)

40 (12.2) 2 (.6)

35 (10.7) 2 (.6)

30 (9.1) 2 (.6)

50 (15.2) 7 (2.1)

45 (13.7) 7 (2.1)

40 (12.2) 7 (2.1)

35 (10.7) 7 (2.1)

Maximum 75 gal.Maximum 48, 65 gal.

Maximum

Length ft (m)

Minimum

Length ft (m)

85 (25.9) 10 (3.1)

80 (24.4) 10 (3.1)

75 (22.9) 10 (3.1)

70 (21.3) 10 (3.1)

90 (27.4) 15 (4.6)

85 (25.9) 15 (4.6)

80 (24.4) 15 (4.6)

75 (22.9) 15 (4.6)

65 (19.8) 12 (3.6)

70 (21.3) 15 (4.6)

Specifications

Part II-Venting Specifications for:

40 Gallon

50 Gallon

Through the Wall

Terminating

# of

Elbows

(excl. vent

term.)

Maximum

straight

Length ft (m)

VENT CONNECTOR LENGTHS FOR 2" (5.1 cm) DIAMETER VENT PIPE

1 30 (9.1)

Through the Wall 2 25 (7.6)

Through the Wall 3

Through the Wall 4 15 (4.6)

Through the Roof 0 35 (10.7)

Through the Roof 1 30 (9.1)

Through the Roof 2 25 (7.6)

Through the Roof 3 20 (6.1)

Vent Tables

Page 8

PDX Series

Minimum

straight

Length ft (m)

2 (.6)

7 (2.1)

IMPORTANT

The minimum equivalent length for the exhaust portion of the vent is 7 feet. The maximum equivalent vent length for the exhaust is 35 feet

for 2" diameter pipe and 85 feet for 3" diameter pipe. The intake portion of the vent must be equal to or less than the vent length of the

exhaust. The tables below are provided for your quick reference, some installations may require a greater number of elbows. When

calculating equivalent vent length, one 90° elbow is equivalent to 5 feet.

20 (6.1)

Through the Wall

Terminating

# of

Elbows

(excl. vent

term.)

Maximum

straight

Length ft (m)

VENT CONNECTOR LENGTHS FOR 3" (7.6 cm) DIAMETER VENT PIPE

1 80 (24.4)

Through the Wall 2 75 (22.9)

Through the Wall 3

Through the Wall 4 65 (19.8)

Through the Roof 5 60 (18.3)

Through the Roof 0 85 (29.9)

Through the Roof 1 80 (24.4)

Through the Roof 2 75 (22.9)

Maximum

straight

Length ft (m)

10 (3.1)

15 (4.6)

70 (21.3)

Through the Roof

3 70 (21.3)

65 (19.8)4

15 (4.6)

Control Timings

Ignition State Timing

Pre-purge 15 Seconds

Trial for Ignition 90 Seconds

Flame Stabilization Period 3 Seconds

Inter-purge 15 Seconds

Flame Failure Response Time 1.5 Seconds (2 second. Maximum; 1 second minimum.)

Post-purge 15 Seconds

PS Fault Delay (failed open/close) Retry after 2 Minutes

Soft Lockout Retry after 5 Minutes

TCO Limit Lockout Indefinite (cycle power to restart)

Simulated Resistive Load Lockout Indefinite (cycle power to restart)

Hardware Error Lockout Indefinite (self clears if fault clears for at least 15 seconds)

Verify Resistive Delay Retry after 2 Minutes (repeats 5 times)

Specifications

Page 9

PDX Series

Sequence of Operation

Thermostat calls for heat.

Prior to energizing blower, gas control checks safety circuit to insure the circuit is open. Normal switch positions

in the safety circuit are as follows:

a) Exhaust pressure switch normally open.

b) Blower temperature switch normally closed.

If the safety circuit is closed, the control waits 4 seconds, gas control LED flashes 2 times with 3 second pause.

Gas control waits 2 minutes then, blower runs for 30 seconds. This cycle repeats until safety circuit opens.

Start Up.

Upon power up, the control runs a safe-start check with a typical start-up delay of 1-5 seconds.

Flammable Vapor Check.

To assure no outputs are energized if the “Flammable Vapor Sensor” is out of range, the control will test the

the “Flammable Vapor Sensor” for proper operating range. If the “Flammable Vapor Sensor” is within range the

control resumes normal operation with no perceptible delay. If the “Flammable Vapor Sensor” is out of range, the

control LED immediately flashes 7 times with 3 second pause.

Blower energizes.

Differential pressure switch proves blower/vent system operation.

a) If the pressure switch does not close within 30 seconds, the control LED Flashes 3 times with 3 second pause.

The blower runs for 30 seconds every 2 minutes trying to get the pressure switch or blower temperature

switch to close. This cycle repeats as long as there is a call for heat.

Blower pre-purge period (15 seconds)

Trial for pilot ignition (90 seconds).

a) The gas control lights the pilot by activating spark igniter and gas flow to pilot burner.

b) If flame is not sensed within 90 seconds, igniter and gas flow are deactivated, blower will post purge and

control LED flashes 6 times with 3 second pause.

Main burner Ignition

After pilot flame is sensed, gas control activates main valve for main burner ignition. The gas control will ignore

flame and pressure switch signals for 3 seconds allowing for main burner to stabilize.

Page 10

PDX Series

Steady state operation.

During Steady State Operation the Control Monitors:

Thermostat temperature sensor- When set point temperature is satisfied, gas valve is shut down and

blower will post purge for 15 seconds. Control LED flashes a short flash once every 4 seconds (idle) status

code.

Pressure switch / Blower temperature switch- If either switch opens, pilot valve and main valve is shut

down. The blower continues to run for 30 seconds attempting to close the circuit. The control LED Flashes

3 times with 3 second pause.

Flame Sense- If flame is lost, pilot & main valve are shut down, blower runs for 15 seconds. Control attempts

to re-light pilot 4 times. If unsuccessful, Blower is shut down and control proceeds to 5 minute lockout. Control

re-attempts to light pilot starting at normal heating sequence #2.

Thermostat satisfies.

Burner off.

Blower post purge (15 seconds).

Sequence of Operation

1. Simulated Resistive Device Fault:

a) If the Flammable Vapor Sensor resistance is greater than 70,000 Ohms - the gas control immediately turns

off all outputs. Control waits and monitors resistance for 30 seconds. If the resistance is greater than 70,000 ohms

after 30 seconds, the gas control pro

ceeds to verify resistive delay for 2 minutes and flashes 7 times with a three

second pause. This process is repeated 5 times until the control either returns to normal operation or proceeds

to a lockout mode flashing 7 times wi

th a 3 second pause.

b) If the Flammable Vapor Sensor resistance is below 3000 ohms - The gas control immediately turns off all

outputs and proceeds to flash 8 times then once with three second pause. The error self clears if the resistance

returns to nor

mal range for at least 15 seconds.

2. Temperature Sensor Fault:

a) Temperature sensor detected open circuit - The gas control Immediately turns off all outputs and proceeds to

flash 8 times then three times with three second pause. The error self clears if the fault clears for at least 15

seconds.

b) Temperature sensors not reading the same

temperature within ±5.5 °F - The gas control Immediately turns off

all outputs and proceeds to flash 8 times then three times with three second pause. The error self clears if the fault

clears for at least 15 seconds.

c) Water temperature in excess of TCO (Temperature Cut Off) limit - The gas

control immediately turns off pilot &

main valve and proceeds to flash 4 times with 3 second pause. Blower continues to run until gas control is reset.

Power needs to be cycled to remove gas control from TCO lockout.

Page 11

PDX Series

Sequence of Operation

3. Pressure Switch/Blower Temperature Fault:

a) Pressure switch closed at start of call for heat - The control waits four seconds then, proceeds to flash

2 times with 3 second pause. The control waits 2 minutes and then turns on blower for 30 seconds. The blower

turns off after 30 seconds and the control waits for pressure switch to open. Any time the Pressure switch opens,

the blower turns on (or stays on) and the control proceeds to waiting for p

ressure switch to close.

b) Pressure switch or blower temperature switch failed open - The control runs the blower for 30 seconds

waiting for the pressure switch and/or blower temperature switch to close. If either switch does not close in 30

seconds, the blower turns off and the control flashes 3 times with 3 second pause. The control waits two

minutes before turning on the blower for another 30 seconds to see the circuit close. This cycle re

peats as long as

there is a call for heat or until the circuit closes.

c) Pressure switch or blower temperature switch opens during burner operation - The control turns off the

pilot and main valve, runs blower for 15 seconds (inter-purge) waiting for pressure switch and/or blower

temperature switch to close. If either switch fails to close, the control proceeds as described in 3b above. If the

circuit closes again by the end of

the inter-purge, the recycle counter is incremented, if the recycle count has

not reached its limit (4), another trial for ignition begins. If the recycle count has been reached, the control

turns off the blower and flashes 6 times then 2 times with 3 second pause. The control waits 5 minutes before

repeating ignition sequence.

4. Trial For Ignition Fault:

a) Pressure switch opens during trial - The control turns off igniter and pilot valve. The gas control proceeds

as described in 3b above. If the pressure switch closes within 30 seconds the gas control will continue with trial for

ignition starting at blower pre-purge.

b) Flame Not Sensed - The control energizes the spark igniter attempting to light the pilot and prove flame. If

lame is not sensed within 90 seconds, the igniter turns off, the pilot valve is closed and the gas control runs the

blower through post purge and flashes 6 times then once with 3 second pause. The control waits 5 minutes before

repeating the ignition sequence.

5. Flame Sensing Fault:

a) Flame lost during run - The control turns off pilot and main valves, runs blower for 15 seconds (inter purge).

The control increments the recycle count, if the recycle count has not reached its limit (4), another trial for

ignition begins. If the recycle count has been reached, the control turns off the blower and flashes 6 times

then 3 times with 3 second pause. The control waits 5 minutes before repeating the ignition sequence.

b) Flame s

ensed out of sequence - the control only looks for pilot flame when the blower is running. If flame is

present when the pilot valve is not open, the control proceeds to wait for flame loss and flashes 5 times with 3

second pause. This continues until flame is lost, once the flame signal is lost, the control flashes 6 times then 4

times with 3 second pause. The control waits 5 min

utes before repeating the ignition sequence.

Page 12

PDX Series

Short flash, once every

four seconds

“Heartbeat”, alternates

bright/dim

Thermostat calling

for heat (no fault).

Short flash once per

second

Weak pilot signal

on last call for heat.

Two flash, three second

pause

Pressure switch not

working-closed

position.

Three flash, three second

pause

Pressure switch or

blower temp.

switch not working

-open position.

Four flash, three second

pause

Excessive tank

temperature.

System must be

reset.

Five flash, three second

pause

Undesired-false

pilot flame present.

Troubleshooting

LED Status

Stand-by mode,

Waiting for call for

heat (no fault).

Control Status

Service

Procedure

Probable Cause

Temperature demand is satisfied

Normal operation.

Adjust thermostat to

temp level

Tank temperature below set point of thermostat.

Normal operation.

Adjust thermostat to

temp level

1. Unstable pilot.

2. Pilot tube block or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

1. Page 15

2-4. Page 17

1. Pressure switch tubing kinked or blocked.

2. Blocked pressure tap on switch or blower.

3. Faulty pressure switch.

Page 18

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Blower not spinning up to speed.

5. Blower temp or exhaust temp too high

6. F

aulty blower temperature switch.

7. Intake vent length exceeds exhaust vent length.

8. Frozen intake or exhaust vent terminal.

1. Check vent or vent tables.

2 & 3 Page 18

4. Page 20

5 & 6 Page 22

8. Page 37

1. Thermal well sensor out of calibration.

2. Faulty gas control.

3. Plumbing leak

1. Page 24

2. Replace gas control,

page 26

1. Pilot valve stuck in open position.

Replace gas control,

page 26

None, control LED not on

or flashing

No electrical

power

Control power switch in “OFF” position.

Supply voltage interrupted.

Turn power on

Page 13

Observe green LED indicator on Electronic gas

control. Error flash codes are displayed with a

three second pause before repeating. Check

and repair the system as noted in the

troubleshooting table

below.

Green LED

Indicator

PDX Series

(For models with serial numbers starting with K or later see chart on page 15.)

Six-four flash, three

second pause

Undesired-false

pilot flame

sensed.

System auto

resets.

Seven flash, three second

pause

Flammable Vapor

Sensor fault

detected

Eight-one flash, three

second pause

Flammable Vapor

Sensor out of

specification.

Thermal well

sensor damaged

or unplugged

Eight-three flash, three

second pause

Gas valve

electronics fault

detected

LED Status Control Status

Service

Procedure

Probable Cause

Pilot valve stuck in open position.

Replace gas control,

page 26

WARNING: EXPLOSION HAZARD

* Indicates gasoline vapors were detected at potentially

explosive levels.

* Verify no gasoline vapors are still present

* Reset the control by cycling power to the appliance or

by cycling the ON/OFF switch

* Replace the Flammable Vapors Sensor element if a

gasoline spill event occurred.

Page 28

* Verify Flammable Vapor Sensor (FVS) resistance is

not below 25 K Ohms.

* Check wiring to FVS and insure it is not shorted.

* Replace control if everything above checks out OK.

Page 28

1. Damage to thermal well wire.

2. Thermal well sensor resistance out of range.

Page 24

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Interrupt power supply

2. Replace gas control,

page 26

Eight-four flash, three

second pause

Gas valve fault

detected.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Interrupt power supply

2. Replace gas control,

page 26

Troubleshooting

Six-three flash, three

second pause

Pilot flame

extinguished.

System auto

resets.

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

5. Insufficient combustion air.

6. Gas pressure is

out of specification.

1. Page 15

2-4. Page 17

5. Refer to installation manual

Page 14

Six-two flash, three

second pause

Pressure switch

or blower temp

switch opened

during burner

operation.

System auto

resets.

1. Check vent or vent tables.

2 & 3 Page 18

4. Refer to venting section of

installation manual

5. Page 20

6 & 7 Page 22

8. Refer to installation

manual.

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Vent termination being affected by wind

5. Blower not spinning up to speed.

6. Blower temp or

exhaust temp too high

7. Faulty blower temperature switch.

8. Insufficient combustion air.

Six-one flash, three

second pause

Failed to light pilot.

System auto resets.

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

1. Page 15

2-4. Page 17

PDX Series

Short flash, once every

four seconds

“Heartbeat”, alternates

bright/dim

Thermostat calling

for heat (no fault).

Short flash once per

second

Weak pilot signal

on last call for heat.

Two flash, three second

pause

Pressure switch not

working-closed

position.

Three flash, three second

pause

Pressure switch or

blower temp.

switch not working

-open position.

Four flash, three second

pause

Excessive tank

temperature.

System must be

reset.

Five flash, three second

pause

Undesired-false

pilot flame present.

LED Status

Stand-by mode,

Waiting for call for

heat (no fault).

Control Status

Service

Procedure

Probable Cause

Temperature demand is satisfied

Normal operation.

Adjust thermostat to

temp level

Tank temperature below set point of thermostat.

Normal operation.

Adjust thermostat to

temp level

1. Unstable pilot.

2. Pilot tube block or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

1. Page 15

2-4. Page 17

1. Pressure switch tubing kinked or blocked.

2. Blocked pressure tap on switch or blower.

3. Faulty pressure switch.

Page 18

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Blower not spinning up to speed.

5. Blower temp or exhaust temp too high

6. F

aulty blower temperature switch.

7. Intake vent length exceeds exhaust vent length.

8. Frozen intake or exhaust vent terminal.

1. Check vent or vent tables.

2 & 3 Page 18

4. Page 20

5 & 6 Page 22

8. Page 37

1. Thermal well sensor out of calibration.

2. Faulty gas control.

3. Plumbing leak

1. Page 24

2. Replace gas control,

page 26

1. Pilot valve stuck in open position.

Replace gas control,

page 26

None, control LED not on

or flashing

No electrical

power

Control power switch in “OFF” position.

Supply voltage interrupted.

Turn power on

Observe green LED indicator on Electronic gas

control. Error flash codes are displayed with a

three second pause before repeating. Check

and repair the system as noted in the

troubleshooting table

below.

Green LED

Indicator

Troubleshooting

PDX Series

Page 15

(The following chart is for models with serial numbers starting with K or later.)

Page 16

Six-four flash, three

second pause

Undesired-false

pilot flame

sensed.

System auto

resets.

Seven flash, three second

pause

Flammable Vapor

Sensor fault

detected

Eight-one flash, three

second pause

Flammable Vapor

Sensor out of

specification.

Eight-three flash, three

second pause

Gas valve

electronics fault

detected

LED Status Control Status

Service

Procedure

Probable Cause

Pilot valve stuck in open position.

Replace gas control,

page 26

WARNING: EXPLOSION HAZARD

* Indicates gasoline vapors were detected at potentially

explosive levels.

* Verify no gasoline vapors are still present

* Reset the control by cycling power to the appliance or

by cycling the ON/OFF switch

* Replace the Flammable Vapors Sensor element if a

gasoline spill event occurred.

Page 28

* Verify Flammable Vapor Sensor (FVS) resistance is

not below 25 K Ohms.

* Check wiring to FVS and insure it is not shorted.

* Replace control if everything above checks out OK.

Page 28

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Interrupt power supply

2. Replace gas control,

page 26

Eight-four flash, three

second pause

Gas valve fault

detected.

1. Control needs to be reset.

2. Control is wet or physically damaged.

1. Interrupt power supply

2. Replace gas control,

page 26

Six-three flash, three

second pause

Pilot flame

extinguished.

System auto

resets.

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

5. Insufficient combustion air.

6. Gas pressure is

out of specification.

1. Page 15

2-4. Page 17

5. Refer to installation manual

Six-two flash, three

second pause

Pressure switch

or blower temp

switch opened

during burner

operation.

System auto

resets.

1. Check vent or vent tables.

2 & 3 Page 18

4. Refer to venting section of

installation manual

5. Page 20

6 & 7 Page 22

8. Refer to installation

manual.

1. Vent blockage or improper vent configuration.

2. Pressure switch tubing kinked or blocked.

3. Faulty pressure switch.

4. Vent termination being affected by wind

5. Blower not spinning up to speed.

6. Blower temp or

exhaust temp too high

7. Faulty blower temperature switch.

8. Insufficient combustion air.

Six-one flash, three

second pause

Failed to light pilot.

System auto resets.

1. Unstable pilot.

2. Pilot tube blocked or restricted.

3. Oxidation build up on pilot electrode.

4. Wire damage to pilot assembly or bad

connection at gas valve.

1. Page 15

2-4. Page 17

Troubleshooting

PDX Series

Eight-two flash, three

second pause

Temperature

sensor damaged

or unplugged

1. Damage to Temperature Sensor.

2. Thermal well sensor resistance out of range.

Page 24

Page 16

Step 1. With main burner in operation, remove outer jacket door remove inner door as described in this manual,

see inner door removal, inspection and replacement section (page 36).

Step 2. To adjust for proper burning, loosen the air shutter nut, rotate the air shutter to close the opening in the

burner, then slowly rotate the air shutter open until flame becomes as blue as possible with a minimum of

yellow tips. Tighten the air shutter nut.

Too much air will cause the flame to lift off the burner ports and create noisy burner operation.

Too little air will result in soot formation.

Step 3. Replace inner door as described in this manual, observe burner operation. Burner should operate as

adjusted in step 2. If not, repeat air shutter adjustment compensating for proper burner operation with inner

door closed.

At periodic intervals (every 6 months) a visual inspection should be made of the pilot and main burner for proper

operation and to assure no debris is accumulating.

Pilot flame should be stable, some causes for an unstable pilot flame are:

a) Water heater vent is less than the allowable vent length.

b) Gas pressure is out of specification.

c) Pilot flame not fully engulfing spark/flame sensor.

d) Door was not sealed properly after servicing.

Main burner should light smoothly from pilot and burn with a blue flame with a minimum of yellow tips.

Steel burner models self adjust air to gas ratio mixture and do not have an adjustable air shutter. Cast iron burner can

have the gas and air mixture properly proportioned by adjusting the air shutter on the mixer face of the main burner

(see cast iron burner adjustment below).

Main burner must be free from any debris accumulation that may effect burner operation (see burner cleaning

procedure on page 14).

Burner Inspection and Air Shutter Adjustment.

Cast Iron Burner Air Shutter Adjustment

WARNING

Inner door and burner components may be HOT when performing this operation. Take

necessary precaution to prevent personal injury.

Air Shutter Nut

PDX SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Air Shutter

Page 17

PDX Series

Burner Cleaning

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall

outlet.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and inner door per service procedure XIII on page 35.

Feedline nut

Pilot tubing nut

Igniter/flame

sense wire

Step 4. Disconnect pilot tube (7/16 wrench) and

feedline (¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sensor wire from gas control.

Step 6. Remove burner assembly from combustion chamber.

Step 7. Thoroughly inspect burner surface area and burner port area and

remove any loose debris.

Step 8. For cast iron burners, inspect for any debris build up inside

burner casting.

Burner

surface area

Burner

port area

Step 9. Unscrew burner from main burner

orifice. On cast iron burners, loosen

air shutter nut and unscrew feedline

from burner.

Step 10. Remove main burner orifice from

feedline (½" wrench on steel

burners, 3/8" wrench on cast iron)

inspect orifice, clean or replace if

necessary.

Step 11. Reassemble burner and reinstall into water heater. Restore gas supply

and check for gas leaks.

Step 12 To resume operation follow the instruction located on the lighting

instruction label or the lighting instruction located in the installation

and operating manual.

PDX SERVICE PROCEDURE I

Burner Operation Inspection,

Adjustment, Cleaning and Replacement

Page 18

L.P. Main burner

orifice. Left hand

thread

Main burner

orifice

PDX Series

PDX SERVICE PROCEDURE II

Pilot testing, Cleaning and Replacement

Pilot Inspection, Testing and Replacement

Step 1. Position gas control power switch to the “OFF” position and unplug heater from wall

outlet.

Step 2. Turn off gas supply to water heater.

Step 3. Remove outer jacket door and remove inner door per service proceedure XIII on page 35.

Feedline nut

Pilot tubing nut

Igniter/flame

sense wire

Step 4. Disconnect pilot tube nut (7/16 wrench) and feedline nut

(¾ wrench) from gas control.

Step 5. Disconnect igniter/flame sense wire from gas control.

Step 6. Remove burner assembly from combustion chamber.

Step 7. Remove pilot assembly from feedline (¼" nut driver).

Step 8. Visually inspect igniter/flame sense wire for damage. Replace

pilot if damage is found.

Step 9. With a multi-meter set to the ohms setting, check continuity

through igniter/flame sense wire. Replace pilot if no continuity.

Step 10. Visually inspect igniter/flame sense electrode for deterioration.

Replace pilot as necessary. Electrode should not be in contact

with pilot hood, If so, carefully adjust electrode to a gap

distance of 3/32" (.09) from pilot hood.

Step 11. Visually inspect igniter/flame sense electrode for oxidation

build up. Carefully clean any oxidation using very fine emery

cloth.

Step 13. Inspect pilot tubing and pilot orifice for blockage:

a) Remove ferrule nut from bottom of pilot assembly (7/16" wrench).

b) Remove pilot tube and pilot orifice.

c) Inspect pilot tubing and pilot orifice for blockage. Clean

or replace as necessary.

Step 14. Reassemble pilot and install to feedline. Reinstall burner assembly to water heater. Restore gas supply

and check for gas leaks.

Step 15 To resume operation follow the instruction located on the lighting instruction label or the lighting

instruction located in the installation and operating manual.

Step 12. Visually inspect pilot tubing for kinks or cracks. If damage is

found replace pilot.

Ferrule

nut

Pilot

orifice

Pilot

hood

Igniter/flame sense

electrode

Igniter/flame sense

wire

Pilot

tubing

Page 19

PDX Series

PDX SERVICE PROCEDURE III

Pressure Switch Testing and

Replacement

Pressure Switch Testing

WARNING

120 volt potential exposure. Use caution

making voltage checks to avoid personal injury.

Step 1. Position power switch on gas control

to the “OFF” position.

Step 2. Remove the three screws (Phillips screw driver) from control access cover on blower assembly and

remove cover (see photo 1).

Step 3. Carefully remove pressure switch from blower housing (see photo 2)

Use a multi-meter set to the

ohms setting. With blower off,

check across pressure

switch terminals.

Are switch contacts open?

(no electrical continuity)

Check tubing and pressure tap

on switch for blockage.

Is there blockage?

Replace switch

(see page 18)

Position gas valve power

switch to the “ON” position

and adjust thermostat

to call for heat,

this will start the blower.

Check with multi-meter, do

pressure switch contacts close

with blower running with the

switch in the vertical

postition?

With steps 1,2 & 3 complete,

disconnect wire leads from

pressure switch.

Switch contacts are OK.

See safety circuit trace

(page 30)

Is vent

system

blocked

See blower testing

(page 21)

Is blower OK?

Clear blockage

Correct blower

problem.

Pressure Switch

Slide pressure switch in direction of

arrow while tilting slightly away

from blower housing.

Is vent system length

within vent table

specifications

listed on page 7 or 8

Reconfigure vent

system to be

compliant with

vent tables.

Pressure switch

wire leads

Page 20

Check tubing and

pressure tap on

switch for blockage.

Is there blockage?

PDX Series

Exhaust pressure

switch

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Bradford White PDX1-40S6FBN User manual

Brand: Bradford White

Model: PDX1-40S6FBN

Category: Water heaters & boilers

Type: User manual

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Bradford White PDX1-40S6FBN User manual

Bradford White PDX1-40S6FBN User manual

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